George Taylor & Co Lifting Gear (Midlands) Ltd GT Viper Lever Hoist Note: The Operator must read and fully understand the operating instructions before using this product. CONTENTS Safety Information Introduction Operating Instructions Operating Instruction Steps Safety Procedures Care & Maintenance Maintenance Checklist Specifications & Dimensions Spare Parts Diagram & List SAFETY INFORMATION SIGNAL WORDS
Note use of the following signal words DANGER,WARNING & CAUTION with safety messages. The appropriate signal word for each has been selected using the following guidelines: DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. The signal word is to be limited to the most extreme situations typically for machine components which, for functional purposes cannot be guarded. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices. CAUTION Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. Every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. You, the operator can avoid many accidents by observing the following precautions in this manual. To avoid personal injury, study the following precautions and insist those working with you, or you yourself, follow them. Replace any Caution, Warning, Danger or Instruction safety label that is not readable or is missing. Do not attempt to operate this equipment under the influence of alcohol or drugs. Review safety instructions with all users. Operator should be a competent person. DO NOT ALLOW PERSONS TO OPERATE OR ASSEMBLE THIS UNIT UNTIL THEY HAVE DEVELOPED A THOROUGH UNDERSTANDING OF SAFETY PRECAUTIONS AND HOW IT WORKS. Never exceed the limit of a lift. If its ability to do a job, or to do so safely is in question - DON T TRY IT. INTRODUCTION UNPACKING Congratulations on your GT Viper Lever Hoist purchase. The GT Viper Lever Hoist you have chosen, is a heavy duty hoist, designed to retain its operational features under normal operating conditions. In order to achieve years of satisfactory service from your GT Viper Lever Hoist a routine of careful operation, regular maintenance and lubrication should be applied. Prior to the operation, installation or maintenance of your GT Viper Lever Hoist, please read all the contents contained within this manual. At all times only competent and experienced personnel should operate, install or maintain this hoist. Failure to comply with the instructions contained within this manual can result in both physical and/or property damage. In keeping with statutory requirements, and best use for your GT Viper Lever Hoist we recommend a periodic maintenance check every 12 months via your local GT branch. GT Lifting Gear UK s experienced and competent personnel can arrange for a complete service including preventative maintenance, spares and repairs service. COMMISSIONING Your GT Viper Lever Hoist has been tested, and complies with our interpretation of the performance requirements of EN13157. On completion of installation, but prior to your GT Viper Lever Hoist being put into regular service, the following procedures should be carried out: 1. Check that all fittings and fasteners are tight and secure. 2. Operate the hoist with both minimum load and full load, and check that the operation is smooth at all times. 3. Check operation of hoist brake, under light load and full load conditions. OPERATING INSTRUCTIONS Principle and Operation of Chain Adjusting System. WARNING IMPROPER Lever Hoist use could result in death or serious injury. To avoid these hazards: NEVER Operate the chain adjusting device while load is applied to Lever Hoist. NEVER Touch the grip ring during lifting or lowering of the load.
NOTE: The brake is engaged automatically during lowering or lifting of the load. In order to activate the brake mechanism, it is necessary to apply the following minimum loads. Lever Hoist Capacity (kgs) Minimum Load to activate brake (kgs) 500 15 750 22.5 1000 30 1500 45 2000 60 3000 90 6000 180 9000 270 OPERATING INSTRUCTIONS STEPS METHOD Principle of Lifting & Lowering Operation By setting the change-over lever to UP or DOWN, and operating the lever, the female thread and the change-over pawl inside the hoist engage and the female thread rotates in either the lifting or lowering direction. The brake works instantly after the lever operation stops and holds the load. Before Lifting a Load: 1. Before the lever hoist is used ensure that the load chain is lightly lubricated. 2. Do not operate the lever hoist unless it is rigged to pull in a straight line from hook to hook. Lifting and Lowering Select direction of movement and ratchet hand lever back and forth, see below: Chain movement Change-over lever Hand lever rotation that produces movement Raise UP Clockwise Down DOWN Counterclockwise
SAFETY PROCEDURES The following Safety section should form part of the safety rules for any plant where any hoist or other lifting equipment is being used, serviced or repaired. Any person/s operating the hoist should read and observe the following safety instructions and the instructions in the Operating section, to avoid operating hazards.
CARE & MAINTENANCE CARE IN USE 1. Always examine the hoist carefully before use - your life may be at stake. Look for cracks or damage, particularly with hooks and load chain. 2. Keep load chain clean and oiled to prevent undue damage or wear. Avoid dragging the load chain through dirt or mud. 3. When the hoist is used outdoors or in a corrosive environment, ensure that it is regularly and adequately lubricated. 4. Do not operate the hoist if you do not have a clear view of the bottom hook and the load. WARNING If a load hook has been distorted, due to an overload on the hoist, the hoist lifting unit will be damaged. A hoist which has been overloaded must be withdrawn from service immediately. MAINTENANCE The maintenance instructions contained in this manual are intended as a guide to the necessary procedures to be carried out by competent and experienced personnel. GT Lifting Gear UK does not accept responsibility either for the manner in which the instructions in this manual are observed or for any consequence there of GT Lifting Gear UK recommends two forms of maintenance to be carried out on your Lever Hoist periodically. The two forms include: 1. A Visual Check (prior to each use); refer to Care In Use information on the left for necessary checks. These checks can be carried out by the operator. 2. A Certified Check (conducted at least every 12 months) ; this type of inspection is to be carried out by authorised GT Lifting Gear UK personnel only. The maximum interval between inspections is one year, but frequency may vary according to legislation in force in the country in which the products are used. In the case of continuous or particularly heavy use the frequency of inspections must be increased accordingly. IMPORTANT NOTE: Always store unit in a clean and dry area. Ensure that all repair and maintenance work is carried out by qualified personnel, using only the specified genuine parts. Points of Inspection Type of Inspection Outcome
Deformation of hook Visual There should be no deformation of the hook. Safety catch should close against the tip of the hook securely. Damage to the hook Visual There should be no crack or serious damage. Bend in the neck of hook Visual Hook should hang square to lifting unit or top hook or to side plates (bottom block). Suspension pin Visual Should not be bent, cracked or worn. Side plates and suspension plates Visual There should be no cracks, damage or wear. Rivets, bolts and nuts Visual All fasteners should be tight. Safety catch Visual Should close properly. Chain Visual Should be properly lubricated and free from bends, nicks or stretch, rust and dust. Chain guide rollers Visual Should rotate freely and keep chain in the pockets of the chain wheel(s). Lifting and lowering Lift and lower a load as per the minimum load chart Hoist should operate smoothly and easily. Pawl should click during lifting. Braking Lift and lower the full rated capacity Lifting and lowering operations should be smooth and without any of the following defects. 1. Load falls if chain is released 2. Load falls whilst lowering 3. Load slips SPECIFICATIONS & DIMENSIONS Capacity (kgs) 500 750 1000 1500 2000 3000 6000 9000 Running test load (kn) Effort Req d to lift rated capacity (N) Standard Lift (m) Load chain falls 7.5 11 15 22.5 30 37.5 75 112.5 340 180 180 380 380 450 500 900 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1 1 1 1 1 1 2 3
Load chain dia (mm) 5 6 6 8 8 10 10 10 A (mm) 105 148 148 172 180 200 200 200 B (mm) 78 90 90 98 105 115 115 115 C (mm) 80 136 136 160 160 180 235 335 D (mm) 35 40 40 44 46 50 64 85 H (mm) 260 320 320 380 380 480 600 740 L (mm) 300 250 250 300 300 375 375 410 K (mm) 25 28 28 38 38 42 50 57 Net Weight (kgs) Extra weight per metre extra lift (kgs) 4 7.4 7.4 11.6 11.6 20 29.4 45 0.52 0.8 0.8 1.4 1.4 2.2 4.4 6.6 SPARE PARTS DIAGRAM SPARE PARTS LIST No. Description No. Description 1 Self locking nut 28 Spring washer 2 Latch spring 29 Hex screw 3 Safety latch 30 Hand wheel 4 Hex bolt 31 Self locking nut 5 500-3000 kgs top hook assembly 32 Long shaft gear 6 Hoist cover assembly 33 Chain cover 7 Disc gear 34 Pawl pin 8 Load shaft 35 Pawl spring
9 Spline gear 36 Pawl 10 Steel bushing 37 Outside handle lever 11 Right side plate 38 Change over pawl 12 Hook shaft 39 Bar 13 Suspension bar 40 Bar spring 14 Load chain sprocket 41 Handle cover fixed nut 15 Guide roller 42 ID plate 16 Solid bearing 43 ID plate rivet 17 Left side plate 44 Bolt 18 Brake base 45 Handle cover 19 Ratchet gear 46 Hex bolt 20 Friction disc 47 End ring 21 Brake disc 48 Load chain 22 Free spring 49 Self locking nut 23 Ratchet gear cover 50 500-3000 kgs bottom hook assembly 24 Inner handle lever 51 6000-9000 kgs bottom hook assembly 25 Retaining pin for shaft 52 6000 kgs top hook assembly 26 Change over gear 53 9000 kgs top hook assembly 27 Outside handle lever TROUBLESHOOTING Problem Cause Solution 1. Chain is jammed Load is not being pulled in a vertical direction Line load to be positioned vertically Pull is at an angle greater than 60 Swivel hook has ceased operating Block is dirty or hampered with foreign matter Fall of chain is tangled Block is overloaded Brake mechanism has jammed Reduce angle of pull a) Unload and de-swivel b) Replace hook assembly Refer to maintenance section of this manual Unravel and straighten chain Load block to recommended capacity only Return to supplier for repair 2. Load is spinning Swivel hook has ceased operating a) Unload and de-swivel b) Replace hook assembly Over spinning Ensure that bolts and hook are properly secured 3. Block seized Wear and tear Replace block Poor maintenance and inspection Poor storage and handling Block is overloaded Refer to manual for maintenance and inspection details Always store unit in a dry clean area Load block to recommended capacity only 4. Slippage of load Brake mechanism worn Return to supplier for repair and testing 5. Block not braking Brake mechanism worn Return to supplier for repair and testing
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